Control device for use in injection molding machine

Abstract

In an injection molding machine configured to extrude a melted resin under temperature control and inject the resin into metal molds to provide a molded product, there are provided an HMI section having a built-in general-purpose operating system and configured to control a display section equipped with a touch panel, control modules, such as a main control section, a sequence processing section and a servo command section, having a dedicated microprocessor for each control element of the injection molding machine, and a driver section having servo amplifiers, hydraulic drivers, and so on, configured to be controlled by the control modules and to drive-control an actuator of the injection molding machine, in which, by variously combining together the control modules, it is possible to provide various kinds of injection-molding machines, that is, an electric operation type, a hydraulic type and a hybrid type of these combination.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application is based upon and claims the benefit of priority from prior Japanese Patent Application No. 2005-117148, filed Apr. 14, 2005, the entire contents of which are incorporated herein by reference.

BACKGROUND OF THE INVENTION

[0002] 1. Field of the Invention

[0003] The present invention relates to a control apparatus for use in an injection molding machine.

[0004] 2. Description of the Related Art Known is, for example, an injection molding machine as disclosed in Jpn. Pat. Appln Kokai Publication NO. 2001-191383.

[0005] An injection molding machine needs various kinds of control in the injection molding, such as the injection, measuring, mold opening and closing, extruding, application of temperature.

[0006] The injection molding machine of the above PUBLICATION performs necessary control in the injection molding by a specific control device usable only for the injection molding machine.

[0007] In the injection molding machine, how to control an actuator in the injection, measuring, mold opening/closing and extrusion operations is decided dependent upon a choice of whether an electric operation type or a hydraulic type is used.

[0008] Thus, the use of such control elements differs according to whether an electric operation type, a hydraulic type or a hybrid type of these is used.

[0009] In the prior art, when the control target is an electric operation type actuator, a dedicated control device has been used and, when the control target is a hydraulic operation, a corresponding special control device has been used.

[0010] In this way, the conventional injection molding device always needs such a dedicated control device and it is difficult to provide a better general-purpose machine of economic benefit.

BRIEF SUMMARY OF THE INVENTION

[0011] It is accordingly the object of the present invention to provide a control device for use in an injection molding machine which, when a control target is changed, can obtain a better module unit for each control element and readily handle such a situation through a combination of those control modules and attain a better general-purpose machine unit of higher economic benefit.

[0012] In one aspect of the present invention there is provided an injection molding machine including heating a synthetic resin material and, injects a predetermined amount of molten synthetic resin material into a melted mold to be obtain molded product, the machine comprising a human/machine interface device having a built-in general-purpose operating system and configured to control a display section, a plurality of control modules having a dedicated microprocessor for each control element of the injection molding machine, and a driver section configured to be controlled by the control module and drive-control an actuator of the injection molding machine, in which various kinds of injection molding control can be performed through a specific combination of various control modules.

[0013] Additional objects and advantages of the invention will be set forth in the description which follows, and in part will be obvious from the description, or may be learned by practice of the invention. The objects and advantages of the invention may be realized and obtained by means of the instrumentalities and combinations particularly pointed out hereinafter.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING

[0014] The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate presently preferred embodiments of the invention, and together with the general description given above and the detailed description of the preferred embodiment given below, serve to explain the principles of the invention.

[0015] FIG. 1 shows a structure of an electric operation type injection molding machine according to one embodiment of the present invention;

[0016] FIG. 2 is a block diagram showing a control device of the injection molding machine body according to the embodiment of the present invention;

[0017] FIG. 3 is a block diagram of a control device of the injection molding machine body when it is used as a hydraulic type injection molding machine in the embodiment above; and

[0018] FIG. 4 is a block diagram of a control device of the injection molding machine body when it is used as a hybrid type injection molding machine.

DETAILED DESCRIPTION OF THE INVENTION

[0019] One embodiment of the present invention will be described below with reference to the accompanying drawing.

[0020] FIG. 1 shows an electrically operated injection molding machine.

[0021] In an injection molding machine body 1, an injection screw 4 is so arranged as to be inserted into a cylindrical barrel 3 equipped with a hopper 2.

[0022] The injection screw 4 is rotatable in the barrel 3 and freely movable forward and backward.

[0023] The barrel 3 communicates at its rear portion with the hopper 2. A synthetic resin material is fed into the barrel through the hopper 2. A plurality of heaters, not shown, are arranged at predetermined intervals on the outer periphery side of the barrel 3. These heaters are adapted to heat the outer periphery of the barrel and melt the resin material thus fed.

[0024] The barrel 3 has an injection nozzle 5 at its forward end to allow the synthetic resin material thus melted to be injected.

[0025] The barrel 3 has its heating temperature controlled by the plurality of heaters to allow the melting degree of the melted resin material to become gradually greater toward the forward end of the barrel 3.

[0026] The injection screw 4 is rotatably driven by a servomotor 6 for injection and moved forward and backward. That is, the servomotor 6 for injection transmits its rotation to a ball screw shaft 11 through a transmission mechanism comprising a pulley 7, a timing belt 8 and a timing pulley 9.

[0027] The ball screw shaft 11 is rotatably provided in a servo bracket 10.

[0028] The ball screw shaft 11 is set in a ball nut 12. The ball nut 12 is fixed by bolts to a thrust box 13.

[0029] The injection screw 4 is rotatably joined at its rear end portion to the thrust box 13 through an S shaft and bearing not shown.

[0030] The S shaft is rotatably connected to the thrust box 13 and mounted to a timing pulley 14.

[0031] Reference numeral 17 shows a servomotor for measuring and the servomotor 17 is attached at its rotation shaft to a pulley 16.

[0032] A timing belt 15 is provided between the timing pulley 14 and the pulley 16.

[0033] The timing pulley 14, timing belt 15 and pulley 16 constitute a transmission mechanism.

[0034] The servomotor 17 moves the injection screw 4 material which is to be injected forward, determing an amount of the melted resin. The servomotor 17 transmits its rotation to the S shaft as set out above through the associated transmission mechanism as set out above to allow the injection screw 4 to be rotated.

[0035] The injection screw 4 allows its forward moving position to be decided by an amount of synthetic resin material injected.

[0036] In the forward position of the barrel 3 are provided a metal mold halves 18 and a device 19 for opening/closing and clamping the metal molds.

[0037] When the melted resin material is injected from the injection nozzle 5, the injection nozzle 5 is pushed into a nozzle inlet 18a of one metal mold half 18. In this state, the injection screw 4 allows its forward end 4a to be moved forward and, by doing so, allows the resin material which is melted in the barrel 3 to be injected from the injection nozzle 5. Thus, the resin material is charged into a cavity 20 defined by the metal mold halves 18.

[0038] The device 19 has a fixing plate 21 that supports one of the metal mold halves 18. A movable plate 23 is provided, which holds a tie bar 22 that in turn supports the fixing plate 21. The movable plate 23 can move toward and away from the fixing plate 21.

[0039] The device 19 attaches the movable plate 23 to a toggle mechanism support plate 25 through a toggle type mold clamping mechanism 24.

[0040] A servomotor 26 is provided on the toggle mechanism support plate 25 to drive the toggle type clamping mechanism 24. Reference numeral 27 shows a mold thickness adjusting mechanism. The mechanism 27 adjusts a mold thickness when the toggle type mold clamping mechanism 24 effects the mold clamping operation.

[0041] In the electrical operation type injection molding machine thus structured, the servomotor 26 is first driven for mold clamping. By doing so, the metal molds 18 start their mold closing operation. And the injection nozzle 5 of the barrel 3 is pushed into the nozzle 18a of the mold halves 18.

[0042] Then, the measuring servomotor 17, while being rotated, moves the injection screw 4 forward and effects the measuring of the melted resin material injected. Then, the servomotor 6 for injection rotates the injection screw 4 to allow the injection of the melted resin.

[0043] The barrel 3 injects the melted resin from the injection nozzle 5 and charges the melted resin into the cavity 20 of the metal molds 18.

[0044] As shown in FIG. 2, a control device of the electrical operation type injection molding machine body 1 includes a main control section 31 for controlling each part, a sequence processing section 32 and a servo command section 33.

[0045] The main control section 31 includes a CPU, ROM, RAM, etc., and allows the management and monitoring of the injection molding machine body 1.

[0046] The sequence processing section 32 has a CPU, ROM, RAM, etc., and allows the control of the operation sequence of the injection molding machine body 1.

[0047] The servo command section 33 has a CPU, ROM, RAM, etc., and allows the control of the injection servomotor 6 and measuring servomotor 17.

[0048] The main control section 31, sequence processing section 32 and servo command section 33 are electrically connected together through a bus line 34.

[0049] The servo command section 33 controls a servo amplifier 35 in a driver section and drives the injection servomotor 6. The rotation and current value of the injection servomotor 6 are detected by a detection section 36.

[0050] The servo command section 33 receives a signal from the detection section 36 and detects the moved position and rotation speed of the injection screw 4 and the current value of the motor. Further, the servo command section 33 performs feedback control based on the thus detected moved position and rotation speed and current value and thus controls the servomotor 6.

[0051] The servo command section 33 controls the servo amplifier in the driver section and drives the servomotor 17 for measurement. The rotation and current value of the measuring servomotor 17 are detected by a detection section 38.

[0052] The servo command section 33 receives a signal from the detection section 38 and detects the moved position and rotation speed of the injection screw 4 and current value of the servomotor. Further, the servo command section 33 performs feedback control based on the moved position and rotation speed and current value of the servomotor and controls the servomotor 17 for measurement.

[0053] An I/O 40, etc., is electrically connected via I/O bus 39 to the sequence processing section 32.

[0054] The main control section 31, sequence processing section 32 and servo command section 33 each constitute a control module with a dedicated microprocessor for each control element.

[0055] The main control section 31 includes a communication interface section and, to the communication interface section, an HMI section 41 as a human/machine interface device is electrically connected through a LAN 42 such as Ethernet (registered trademark name).

[0056] The HMI section 41 includes a CPU, ROM, RAM, etc., and general-purpose OS (operating system).

[0057] The HMI section 41 is comprised of, for example, a personal computer and connected to a display section 43 with a touch panel on a liquid crystal display screen to allow the display screen to be controlled.

[0058] The main control section 31 is connected by a cable 45 to an operation panel section 44 with a plurality of mechanical operation switches provided on it.

[0059] The main control section 31 is connected by a cable 46 to the touch panel of the display section 43.

[0060] The main control section 31 is connected by a cable 48 to a temperature control section 47. The temperature control section 47 controls the heating temperature by the plurality of heaters arranged on the outer periphery side of the barrel 3.

[0061] The display section 43 allows the display control by the HMI section 41 and allows its touch panel to be controlled by the main control section 31.

[0062] The display section 43 outputs a key signal to the main control section 31 by finger-touching any corresponding key on the touch panel on the display screen.

[0063] In such an arrangement, the main control section 31 controls the temperature control section 47. The temperature control section 47 controls the heating temperature by the plurality of heaters to allow the melting of the synthetic resin material charged from the hopper 2 into the barrel 3.

[0064] When the resin material is charged from the injection nozzle 5 of the barrel 3 into the cavity 20, the sequence processing section 32 and servo command section 33 are controlled.

[0065] First, the servo command section 33 controls the servo amplifiers 37 and drives the measuring servomotor 17. The servomotor 17 rotates the injection screw 4 to move the melted resin forward and determine the melted resin amount injected from the barrel 3.

[0066] Then the injecting servomotor 6 is driven to, while rotating the injection screw 4, move the resin forward. The injection screw 4 pushes the melted resin into the injection nozzle 5 through the forward end 4a. By doing so, the mold cavity 20 is filled with the melted resin which is injected from the injection nozzle 5 past the nozzle inlet 18a of the mold halves 18.

[0067] When the filling of the melted resin material is finished, the device 19 is operated for the closing and clamping of the mold halves 18, and the mold halves 18 are moved apart from the barrel 3. The device 19 opens the metal molds and a molded product is taken out from the metal mold halves 18.

[0068] This is an operation for the electrical operation type injection molding machine. It is possible to use a hydraulic type injection molding machine in place of the electrical operation type injection molding machine.

[0069] In the case of the hydraulic type injection molding machine, use is made of a hydraulic driver for relief/flow control. It is, therefore, not necessary to use the injection servomotor 6 and measuring servo motor 17.

[0070] A control device of the hydraulic type injection molding machine body does not use the servo command section 33 and servo amplifiers 35, 37 connected to the section 33 as well as the injection servomotor 6, measuring servomotor 17 and so on.

[0071] As shown in FIG. 3, the control device disconnects, from a circuit, the servo command section 33 and servo amplifiers 35, 37 connected to the section 33 as well as the injection servomotor 6 and measuring servomotor 17 and so on and, instead, connects a hydraulic I/O 51 to a bus line 34. In this case, the hydraulic I/O 51 is connected to hydraulic drivers 52 and 53.

[0072] The hydraulic driver 52 moves, forward and backward, the injection screw 4 which injects the molted resin, while, on the other hand, the hydraulic driver 53 moves, forward and backward, the injection screw which also measures an amount of melted resin injected.

[0073] Where the injection molding machine is changed from the electric operation type injection molding machine to the hydraulic type injection molding machine, a change is made from the injection screw 4 driven by the injection servomotor 6 to an injection screw driven under a hydraulic pressure. As an actuator, use is made of an entirely different structure.

[0074] That is, a barrel 3 of different structure is employed in the hydraulic type injection molding machine compared to the electrical operation type injection molding machine. That is, the injection molding machine per se has to be wholly replaced.

[0075] However, the control device has a dedicated CPU each for the main control section 31, sequence processing section 32 and servo command section 33 and provides a control module, that is, a unit modularized for each control element. Therefore, the main control section 31, sequence processing section 32 and servo command section 33 in the main control device are individually exchangeable.

[0076] When, in this way, the injection molding machine is changed from the electrical operation type to the hydraulic type, then the servo command section 33 and so on are disconnected from an associated circuit and, instead, the hydraulic I/O 51 is connected to the bus line 34. The hydraulic I/O 51 is connected to hydraulic drivers 52 and 53. If, in this case, the sequence processing section 32 differs in the electrical operation type injection molding machine and in the hydraulic type injection molding machine, use is made of a hydraulic type sequence processing section 32.

[0077] Even if a change is made from the electrical operation type injection molding machine to the hydraulic type injection molding machine, it is not necessary to wholly replace the control device and, in this case, an exchange may be made in control module units.

[0078] It is also possible for the injection molding machine to use any proper electrical operation type/hydraulic type combination as a hybrid type injection molding machine.

[0079] In the hybrid type injection molding machine, a control device is of such a type that, as shown in FIG. 4, a hydraulic I/O 51 is connected to a bus line 34 as in the control device shown in FIG. 2. The hydraulic I/O 51 is connected to the hydraulic drivers 52 and 53. Further, a sequence processing section 32 is replaced by a hybrid type. As is evident from the above, it is not necessary to replace the control device as a whole.

[0080] Incidentally, the sequence processing section 32 has initially a built-in sequence control program corresponding to an electrical operation, a hydraulic and a hybrid type and it is so constructed as to be able to select any corresponding sequence control program.

[0081] According to such a structure, the sequence processing section 32 is not replaced by a new one and it can be readily handled by selecting any sequence control program.

[0082] As evident from the above, even if the injection molding machine is changed to any of the electrical operation, hydraulic and hybrid type, the control device need not be changed as a whole and it is possible to readily handle this case through the change of any possible control module combination. By doing so, the resultant control device provides an excellent general-purpose device with a higher economic advantage.

[0083] Further, this control device can readily achieve an enhanced processing capability, as required, by the individual exchange of the main control section 31 and sequence processing section 32.

Claims

1. A control device for use in an injection molding machine that melts synthetic resin material and injects a predetermined amount of molten synthetic resin material into a metal mold to obtain a molded product, comprising: a plurality of exchangeable control modules configured to be mutually connected by a bus line and having a dedicated microprocessor for each control element in the injection molding machine; a human/machine interface device configured to be connected to one of the respective control modules and having a general-purpose operating system configured to control a display section; and a driver section configured to be connected to one of the respective control modules to be controlled by the connected control module and to drive-control an actuator of the injection molding machine, in which said plurality of control modules are configured to, in any combination, control the melting of the synthetic resin material in a barrel of the injection molding machine, control the an amount of the melted resin to be injected, and control the injection of the measured resin from an injection nozzle of the barrel.

2. A control device according to claim 1, wherein one of said plurality of control modules is comprised of a main control section configured to control each part and connected to the human/machine interface device.

3. A control device according to claim 1, wherein one of said plurality of control modules is comprised of a sequence processing section configured to control an operation sequence of the injection molding machine.

4. A control device according to claim 1, wherein one of said plurality of control modules comprises a servo command section connected to a driver section, said driver section being configured to rotation-control a measuring servomotor configured to drive the injection screw to inject a predetermined amount of the melted resin and an injection servomotor configured to drive the injection screw to inject the melted resin from the injection nozzle.

5. A control device according to claim 1, wherein one of said plurality of control modules comprises a hydraulic I/O configured to be connected to a driver section, the hydraulic I/O being configured to control a hydraulic driver for driving the injection screw to inject a predetermined amount of the melted resin and a hydraulic driver for driving the injection screw to inject the melted resin from the injection nozzle.

6. A control device according to claim 1, wherein a display section controlled by the human/machine interface device is comprised of a display section having a touch panel set on a liquid crystal display screen.

7. A control device according to claim 2, wherein the main control section is configured to, under a temperature control section, control the temperature of the barrel for allowing the melting of the synthetic resin material through the application of heating.